CN112077336B - Method for accurately identifying cutting force coefficient in ultrasonic vibration-assisted machining - Google Patents
Method for accurately identifying cutting force coefficient in ultrasonic vibration-assisted machining Download PDFInfo
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- CN112077336B CN112077336B CN202010856577.8A CN202010856577A CN112077336B CN 112077336 B CN112077336 B CN 112077336B CN 202010856577 A CN202010856577 A CN 202010856577A CN 112077336 B CN112077336 B CN 112077336B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B1/00—Methods for turning or working essentially requiring the use of turning-machines; Use of auxiliary equipment in connection with such methods
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B5/00—Turning-machines or devices specially adapted for particular work; Accessories specially adapted therefor
Abstract
The invention discloses a method for accurately identifying a cutting force coefficient in ultrasonic vibration-assisted machining, which comprises the following steps of: s1, obtaining actual processing parameters under the ultrasonic vibration auxiliary processing condition according to the ultrasonic vibration auxiliary processing condition; s2, obtaining the shear stress and the normal stress of the front tool face of the tool according to the stress distribution of the contact area of the tool and the workpiece; s3, obtaining cutting force according to the obtained shear stress and normal stress; and S4, obtaining the cutting force coefficient in the ultrasonic vibration auxiliary machining according to the cutting force. According to the invention, the actual processing parameters under the ultrasonic vibration assisted processing condition are obtained according to the influence of the ultrasonic vibration assisted processing ultrasonic vibration on the processing parameters, the cutting force in the ultrasonic vibration assisted processing is obtained according to the stress analysis of the contact of the cutter and the workpiece, the accurate acquisition of the cutting force coefficient in the ultrasonic vibration assisted processing is realized according to the cutting force, and a powerful basis is provided for the processing analysis under the ultrasonic vibration assisted processing condition.
Description
Technical Field
The invention relates to the field of machining, in particular to a method for accurately identifying a cutting force coefficient in ultrasonic vibration-assisted machining.
Background
The ultrasonic vibration assisted machining can obviously reduce the cutting force and the cutting temperature, improve the stability in machining, prolong the service life of a cutter and improve the machining efficiency, and is widely used for machining various high-strength and high-hardness materials. In order to accurately evaluate the cutting heat in the ultrasonic vibration-assisted machining, it is necessary to accurately obtain the cutting force coefficient in the ultrasonic vibration-assisted machining. The existing cutting force coefficient is obtained through a cutting experiment, and the cutting force and the cutting heat are calculated according to the cutting force coefficient. The cutting force coefficients of different ultrasonic vibration parameters are different, and the cutting parameters under the influence of the ultrasonic vibration also have obvious difference on the cutting force and the heat. The existing cutting force coefficient test cannot realize accurate prediction of cutting force and heat, and therefore the cutting force coefficient in ultrasonic vibration auxiliary machining needs to be accurately obtained.
Disclosure of Invention
The present invention is directed to solving at least one of the problems of the prior art. Therefore, the invention provides a method for accurately identifying the cutting force coefficient in ultrasonic vibration-assisted machining, which can accurately acquire the cutting force coefficient under the ultrasonic vibration-assisted machining condition.
The method for accurately identifying the cutting force coefficient in the ultrasonic vibration assisted machining according to the first aspect of the invention comprises the following steps: s1, obtaining actual processing parameters under the ultrasonic vibration auxiliary processing condition according to the ultrasonic vibration auxiliary processing condition; s2, obtaining the shear stress and the normal stress of the front tool face of the tool according to the stress distribution of the contact area of the tool and the workpiece; s3, obtaining cutting force according to the obtained shear stress and normal stress; and S4, obtaining the cutting force coefficient in the ultrasonic vibration auxiliary machining according to the cutting force.
The method for accurately identifying the cutting force coefficient in the ultrasonic vibration assisted machining according to the embodiment of the invention has the following technical effects: according to the influence of ultrasonic vibration assisted machining on machining parameters, actual machining parameters under the ultrasonic vibration assisted machining conditions are obtained, the cutting force in the ultrasonic vibration assisted machining is obtained according to the stress analysis of the contact of the cutter and the workpiece, the accurate obtaining of the cutting force coefficient in the ultrasonic vibration assisted machining is realized according to the cutting force, and a powerful basis is provided for the machining analysis under the ultrasonic vibration assisted machining conditions.
According to some embodiments of the invention, the positive stress on the rake face of the tool in the region where the tool contacts the workpiece is:
the shear stress is:
σsis the positive stress yield strength of the material, /)xIs the distance between the target point and the end point of the contact length of the tool with the chip, tausIs the yield shear stress of the workpiece material; k is a constant and is determined by the property between the workpiece and the cutter; mu.ssThe friction coefficient of the cutter and the workpiece is; l1For the length of contact of the shearing zone with the rake face of the tool,/2The contact length of the slippage area and the front tool face of the tool.
According to some embodiments of the invention, the positive pressure perpendicular to the tool rake surface is:
the shear stress of the front tool face of the tool is as follows:
wherein
lv,tThe contact length of the cutter and the cutting chip under ultrasonic vibration is adopted;
h is the set depth of cut, hvIs the ultrasonic vibration amplitude; f. ofvIs the ultrasonic vibration frequency, theta is the phase angle of the ultrasonic vibration, and t is the time; b is the width of the tool, and A is the contact area of the tool and the workpiece.
According to some embodiments of the invention, wherein the coefficient of friction of the tool with the chip is:
the average friction angle under ultrasonic vibration was: beta is av1＝arctan(us)。
According to some embodiments of the invention, the cutting force in the tool feed direction is:
the cutting force in the cutting speed direction was:
αvis the effective rake angle of the cutter under ultrasonic vibration;
θ1is the angle between the cutting speed under ultrasonic vibration assisted machining and the cutting speed under non-ultrasonic vibration assisted machining.
According to some embodiments of the invention,/v,tThe following relational expression is satisfied,
h1＝h+hvsin(2πfvt+θ)；
wherein h is1Is the actual cutting depth under ultrasonic vibration;
φvthe effective shearing angle of the lower cutter is processed by ultrasonic vibration assistance;
βvthe instantaneous friction angle of the lower cutter is processed in an auxiliary mode through ultrasonic vibration.
According to some embodiments of the invention, phiv、αvAnd betavThe following formula is satisfied:
αv＝α+θ1；
φv＝φ+θ1；
vv＝2πfvhv；
vt＝2πnDr；
wherein n is the rotation speed of the workpiece，DrIs the radius of the workpiece, vtCutting speed, v, set for the toolvThe ultrasonic vibration speed; alpha is the front angle of the cutter without the assistance of ultrasonic vibration; phi is the cutter shearing angle without the assistance of ultrasonic vibration.
Additional aspects and advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
Drawings
The invention is further illustrated with reference to the following figures and examples.
FIG. 1 is a schematic view of a feed direction ultrasonic vibration assisted process;
FIG. 2 is a schematic view of a feed direction ultrasonic vibration assisted machining cut;
FIG. 3 is a schematic view of ultrasonic vibration assisted turning at various cutting speeds;
FIG. 4 is a schematic diagram of cutting speeds in ultrasonic vibration assisted right angle cutting;
FIG. 5 is a graph showing the cutting speed in ultrasonic vibration assisted cutting;
FIG. 6 is a schematic view of the contact area between the chip, the workpiece, and the tool;
FIG. 7 is a schematic view of the chip, tool interface forces.
Detailed Description
Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to the same or similar elements or elements having the same or similar function throughout. The embodiments described below with reference to the accompanying drawings are illustrative only for the purpose of explaining the present invention, and are not to be construed as limiting the present invention.
In the description of the present invention, it is to be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "axial", "radial", "circumferential", and the like, indicate orientations and positional relationships based on the orientations and positional relationships shown in the drawings, and are used merely for convenience in describing the present invention and for simplicity in description, and do not indicate or imply that the device or element so referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore, should not be construed as limiting the present invention. Furthermore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the present invention, "a plurality" means two or more unless otherwise specified.
In the description of the present invention, it should be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Referring to fig. 1 to 7, a method for accurately identifying a cutting force coefficient in ultrasonic vibration assisted machining according to an embodiment of the present invention includes the steps of:
and S1, obtaining actual processing parameters under the ultrasonic vibration auxiliary processing condition according to the ultrasonic vibration auxiliary processing condition.
S2, obtaining the shear stress and the normal stress of the front tool face of the tool according to the stress distribution of the contact area of the tool and the workpiece;
s3, obtaining cutting force according to the obtained shear stress and normal stress;
and S4, obtaining the cutting force coefficient in the ultrasonic vibration auxiliary machining according to the cutting force.
Specifically, step S1 is described in detail below.
Referring to fig. 1 and 2, in ultrasonic vibration assisted right-angle turning, ultrasonic vibration vibrates in the feed direction of a tool, and the tool machining schematic and the right-angle cutting principle thereof are shown in fig. 1 and 2. The set cutting depth is h, and the ultrasonic vibration amplitude in the feeding direction is hvThe frequency of the ultrasonic vibration in the feed direction is fvThe cutting tool is set to a cutting speed vt. The depth of cut is substantially the same as the feed per tooth for the same tool.
The real cutting speed after the ultrasonic vibration assisted machining is v, the cutting depth is h, and the feed amount is fz。
And f isz＝h+hvsin(2πfvt+θ)。
θ is the phase angle of the ultrasonic vibration, and t is time.
In ultrasonic vibration-assisted cutting, the undeformed chip thickness is LuThe method comprises the following steps: l isu＝fz(ii) a Depth of cut (i.e., undeformed chip thickness) h depends on the relationship between turning and right-angle cutting1Comprises the following steps: h is1＝Lu。
That is, in the ultrasonic vibration assisted cutting, the cutting depth:
h1＝h+hvsin(2πfvt+θ)。
in ultrasonic vibration turning, the cutting speed v set by the tooltUltrasonic vibration velocity vvThe relationship between the cutting speed v of the ultrasonic vibration-assisted lower cutter is shown in fig. 3.
vv＝2πfvhv；
vt＝2πnDr；
n is the rotation speed of the workpiece, DrIs the radius of the workpiece.
v＝vt+vvcos(2πfvt+θ)；
Theta is a phase angle of the ultrasonic vibration;
the angle between the cutting speed in ultrasonic vibration-assisted machining and the cutting speed in conventional machining (without ultrasonic vibration assistance) is:
the original rake angle of the tool is alpha, and the cutting speed v set by the tooltUltrasonic vibration speedDegree vvThe relationship between the cutting speed v of the ultrasonic vibration-assisted lower cutter is shown in fig. 4. Effective rake angle alpha of the toolvI.e. the chip flow angle along the tool rake face, is:
αv＝α+θ1
the effective shearing angle of the cutter under the ultrasonic vibration auxiliary processing is as follows:
φv＝φ+θ1。
based on the set processing parameters, the actual processing parameters under the ultrasonic vibration assisted processing conditions in step S1 can be obtained according to the above relation: h is1、φv、αvAnd v.
The shearing angle is determined by cutting parameters, namely material attributes, and according to an analytic model of the shearing angle, the shearing angle under the conventional processing is as follows:
where χ is the propagation velocity of sound in the medium, τsH is the undeformed chip thickness (i.e., depth of cut), v is the shear strength of the materialcC is the specific heat melting of the material, rho is the density of the material, and k is the thermal conductivity of the material. Xi1And xi2The material is determined by the thermodynamic properties of the material, can be respectively defined as the influence coefficient of the shear strength on the shear angle, and the influence coefficient of the shear area on the shear angle is determined by the properties of the material and can be obtained through experimental tests.
During cutting, the contact area between the cutter and the chip can be divided into two parts, the first part is a bonding area, and the contact length of the bonding area and the cutter is set to be l1. In this region, the positive pressure perpendicular to the tool rake face is sufficiently great that the chip can yield to a bending deformation, the frictional stress reaching the yield stress of the material, the plastic deformation occurring in this part of the region. The second partial region is a wiping region.
The contact stress distribution of the two regions, and the positive stress is shown as the formula:
the shear stress is as follows:
wherein sigmasIs the positive stress yield strength of the material, /)xIs the distance between the target point and the end point of the contact length of the tool with the chip, tausIs the yield shear stress of the workpiece material; k is a constant and is determined by the property between the workpiece and the cutter; mu.ssThe friction coefficient of the cutter and the workpiece is; as shown in FIG. 6, the workpiece and tool area is divided into a shear area (shear band) and a slip area, l1For the contact length of the shear area (shear band) with the rake face of the tool,/2The contact length of the slippage area and the front tool face of the tool.
At a certain cutting speed, the length of the cutter with obvious color change of the cutting edge of the front cutter surface in the cutter is analyzed, namely the distance extending from the cutting edge to the cutter body. This is due to the fact that the chip is in contact with the rake face of the tool, which inevitably increases the friction between the tool and the chip, and the temperature at the point of frictional contact of which inevitably increases, which inevitably changes the color of the cutting edge of the tool, i.e. changes the color, but not the length of the scratch mark, i.e./1. This discoloration reaction corresponds to the shear zone of the chip, corresponding to the bond zone of the tool. As the workpiece material in the contact friction area of the cutter and the chips generates certain shearing deformation, the chips slide on the cutter and have certain temperature rise, but the color of the front cutter surface of the cutter cannot be promoted to be changed, and the chips slide on the cutter, so that the cutter has scraping marks, namely the length of the scraping marks extending from the cutting edge to the cutter body is the length of the chips sliding and rubbing on the cutter, namely l2. The slip friction zone corresponds to the slip zone of the chip, corresponding to the scraping zone on the tool.
In conventional machining, the contact length of the tool with the workpiece is approximated as a function of the undeformed cutting thickness h, the shearing angle phi, the rubbing angle beta, and the tool rake angle alpha, as follows:
lcthe contact length of the cutter and the workpiece in the conventional machining.
At an instant of the ultrasonic vibration assisted machining, it is considered that a conventional cutting machining of the tool along a composite speed of the ultrasonic vibration speed and the cutting speed, that is, a change in the contact length of the tool with the workpiece is caused due to a change in the composite speed in the cutting machining.
In the ultrasonic vibration-assisted machining, at a certain time, the contact length of the tool with the chips is
αvIs the effective rake angle of the cutter under ultrasonic vibration; phi is avThe effective shearing angle of the lower cutter is processed by ultrasonic vibration assistance; beta is avThe instantaneous friction angle of the lower cutter is processed in an auxiliary mode through ultrasonic vibration.
During ultrasonic vibration assisted machining, there are the following associated speeds: cutting speed V and shear plane moving speed V in ultrasonic vibration auxiliary machinings2. Shear rate (moving speed of chip relative to workpiece) VsSpeed V of movement of the chip relative to the toolcAs shown in fig. 4.
In a conventional cutting process, the shear angle is calculated according to the principle of minimum energy, and is as follows:
at a certain moment in the ultrasonic vibration-assisted machining, the instantaneous friction angle betavComprises the following steps:
at a certain instant in the ultrasonic vibration-assisted machining, the length of the contact region is lv,tWherein
lv,t＝l1+L2
The normal stress perpendicular to the rake face is:
defining symbolic functions
Then at some point the positive pressure perpendicular to the rake face of the tool is:
where b is the width of the tool, i.e., the cutting width.
The shear stress of the front tool face of the tool is as follows:
the shear stress of the front tool face of the tool is as follows:
a is the contact area of the cutter and the workpiece.
The ultrasonic vibration assists the processing process, and the friction coefficient of the tool and the cutting chip is
The average friction angle under ultrasonic vibration was:
βv1＝arctan(us)；
according to the closed-loop formula, the friction coefficient and the average friction angle under ultrasonic vibration can be obtained.
According to the cutting force diagram in FIG. 2, the cutting force in the feed direction of the tool
The cutting force coefficient in the feed direction of the tool is:
the tangential force in the cutting speed direction is:
the tangential force coefficient in the cutting speed direction is:
in the description herein, references to the description of the term "one embodiment," "some embodiments," "an illustrative embodiment," "an example," "a specific example" or "some examples" or the like are intended to mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
While embodiments of the invention have been shown and described, it will be understood by those of ordinary skill in the art that: various changes, modifications, substitutions and alterations can be made to the embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.
Claims (5)
1. A method for accurately identifying a cutting force coefficient in ultrasonic vibration-assisted machining is characterized by comprising the following steps of:
s1, obtaining actual processing parameters under the ultrasonic vibration auxiliary processing condition according to the ultrasonic vibration auxiliary processing condition;
s2, obtaining the shear stress and the normal stress of the front tool face of the tool according to the stress distribution of the contact area of the tool and the workpiece;
s3, obtaining cutting force according to the obtained shear stress and normal stress;
s4, obtaining a cutting force coefficient in the ultrasonic vibration auxiliary machining according to the cutting force;
in the contact area of the cutter and the workpiece, the positive stress of the front cutter face of the cutter is as follows:
the shear stress is:
σsis the positive stress yield strength of the material, /)xIs the distance between the target point and the end point of the contact length of the tool with the chip, tausIs the yield shear stress of the workpiece material; k is a constant; mu.ssThe friction coefficient of the cutter and the workpiece is; l1For the length of contact of the shearing zone with the rake face of the tool,/2The contact length of the slippage area and the front tool face of the tool is shown;
the positive pressure perpendicular to the rake face of the tool is:
the shear stress of the front tool face of the tool is as follows:
wherein
lv，tThe contact length of the cutter and the cutting chip under ultrasonic vibration is adopted;
h is the set depth of cut, hvIs the ultrasonic vibration amplitude; f. ofvIs the ultrasonic vibration frequency, theta is the phase angle of the ultrasonic vibration, and t is the time; b is the width of the tool, and A is the contact area of the tool and the workpiece.
2. The method for accurately identifying a coefficient of cutting force in ultrasonic vibration-assisted machining according to claim 1, wherein the coefficient of friction of the tool with the chip is:
the average friction angle under ultrasonic vibration was: beta is av1＝arctan(us)。
3. The method for accurately identifying the coefficient of cutting force in ultrasonic vibration-assisted machining according to claim 2, characterized in that the cutting force in the tool feed direction:
the cutting force in the cutting speed direction was:
αvis the effective rake angle of the cutter under ultrasonic vibration;
θ1is the angle between the cutting speed under ultrasonic vibration assisted machining and the cutting speed under non-ultrasonic vibration assisted machining.
4. The method for accurately identifying a cutting force coefficient in ultrasonic vibration-assisted machining according to claim 3, wherein/v，tThe following relational expression is satisfied,
h1＝h+hvsin(2πfvt+θ)；
wherein h is1Is the actual cutting depth under ultrasonic vibration;
φvthe effective shearing angle of the lower cutter is processed by ultrasonic vibration assistance;
βvthe instantaneous friction angle of the lower cutter is processed in an auxiliary mode through ultrasonic vibration.
5. The method for accurately identifying the coefficient of cutting force in ultrasonic vibration-assisted machining according to claim 4, characterized in that φv、αvAnd betavThe following formula is satisfied:
αv＝α+θ1；
φv＝φ+θ1；
vv＝2πfvhv；
vt＝2πnDr；
wherein n is the rotation speed of the workpiece, DrIs the radius of the workpiece, vtCutting speed, v, set for the toolvThe ultrasonic vibration speed; alpha is the front angle of the cutter without the assistance of ultrasonic vibration; phi is the cutter shearing angle without the assistance of ultrasonic vibration.
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